Warpage Simulation of Overmolding Injection Compression Molded PMMA/PC Composite Panels

doi:10.19491/j.issn.1001-9278.2021.04.010

Abstract

Abstract:

A joint simulation method was established on the basis of the Moldflow and ABAQUS softwares to analyze the warpage of overmolding injection-compression molded PMMA/PC composite panels. The numerical simulation of the warpage was carried out through a two-step method. The filling， packing and cooling stages during the overmolding injection compression molding process were first analyzed by the Moldflow software. The temperature field of the demol-ded part and the grid file obtained from the Moldflow analysis were then imported into the ABAQUS software to calculate the warpage when the composite panels were completely cooled to room temperature after demolding. The warpage resulting from the stress release and complete cooling were linearly added to obtain the final value. Meanwhile， the war-page of the part was measured through an injection-molding experiment. The results indicated that the joint simulation was in good agreement with the experimental results.

Key words: overmolding injection compression molding, warpage, simulation, polymethylmethacrylate, polycarbonate

CLC Number:

TQ 320.66

SUN Qiwei, CHEN Yuhong, DONG Shuyuan, LANG Jianlin, ZHOU Xiaowei, ZHANG Yun. Warpage Simulation of Overmolding Injection Compression Molded PMMA/PC Composite Panels[J]. China Plastics, 2021, 35(4): 53-59.

Figures/Tables 12

Fig.1. Warpage restraint surface for stress release during demolding

Fig.2. Flow chart of the forming sequence of PMMA/PC composite panel

材料	密度/kg·m^-3	弹性模量/MPa	泊松比	比热/J·（kg·C）^-1	导热系数/W·（m·C)^-1	热膨胀率
PC	1 190	2 280	0.417	1 880	0.250	7.3×10^-5
PMMA	1 176	2 256	0.341	1 600	0.215	1.39×10^-4

Tab.1. Physical properties of PC and PMMA

Fig.3. Grid model of PMMA/PC composite panel

Fig.4. Overmolding injection compression molded PMMA/PC composite panel

Fig.5. SEM of the PMMA/PC interface of the composite flat panel under different magnifications

Fig.6. Schematic diagram of maximum warpage measurement of composite panel during demolding

Fig.7. Initial stress distribution of the composite panel during demolding

Fig.8. Warpage of the composite panel after stress release by ABAQUS

Fig.9. Warpage of the composite panel after demolding by ABAQUS

Fig.10. Warpage distribution of composite panel

计算模拟方法

翘曲值/mm

Moldflow模拟

ABAQUS计算（脱模时应力释放）

ABAQUS计算（脱模后的翘曲值）

4.49

-3.15

6.75

Tab.2. Warpage of the composite panel by numerical simulation and injection experiment

References 23

1	石琳. 现代飞机风挡及舱盖透明材料的发展［J］. 航空制造工程，1994，（12）：26⁃27.
	SHI L. Development of Transparent Materials for Modern Aircraft windshields and Canopies［J］. Aviation Production Engineering， 1994，（12）：26⁃27.
2	颜悦，厉蕾. 航空座舱透明材料应用研究新进展［M］. 国防工业出版社，2011：5⁃8.
3	李钊，厉蕾. 透明聚氨酯中间层的微观结构对层合玻璃光学性能的影响［J］. 高分子材料科学与工程，1995，（4）：133⁃137.
	LI Z， LI L. The Effect of Microstructure of Interlayer PU on The Optical Characteristics of Laminated Plastic Articles［J］. Polymer Materials Science & Engineering， 1995，（4）：133⁃137.
4	胡开元. 双色注塑技术及其应用研究［D］. 江苏：江苏大学，2010.
5	彭响方，许超，林逸全. 多组分注射成型新技术［J］. 工程塑料应用，2004，32（9）：32⁃35.
	PENG X F， XU C， LIN Y Q. New Technologies of Multi⁃component Injection Molding［J］. Engineering Plastics Application， 2004，32（9）：32⁃35.
6	李健辉. 基于表面模型的塑料注射成型残余应力与翘曲变形研究［D］. 武汉：华中科技大学，2009.
7	周华民，刘芬，李德群. 塑料注射成型应力与翘曲的集成模拟［J］. 塑性工程学报，2008，15（2）：84⁃89.
	ZHOU H M， LIU F， LI D Q. An Integrated Simulation of Residual Stress and Warpage for Plastic Injection Molding［J］. Journal of Plasticity Engineering，2008，15（2）：84⁃89.
8	YOUNG W B. Effect of Process Parameters on Injection Compression Molding of Pick up Lens［J］. Applied Mathematical Modelling， 2005， 29（10）： 955⁃971.
9	BARGHIKAR H， MOSADDEGH P. Experimental and Simulation Study on The Optimum of The Geometrical Quality of Bi⁃convex and Bi⁃concave Lenses Produced by Injection Molding Process［J］. Journal of the Brazilian Society of Mechanical Sciences and Engineering， 2019，41（1）：24.
10	MOSADDEGH B H， MASOUMI P. et al. The Effect of Packing Phase and Mold Temperature on The Directional Warpage of Spherical Lenses Using The Injection Molding Process［J］. SN Applied Sciences，2019，1（6）：598.
11	MARTOWIBOWO S Y， KHLOEUM R. Minimum Warpage Prediction in Plastic Injection Process using Taguchi Method and Simulation［J］. Manufacturing Technolegy，2019，19（3）： 469⁃476.
12	ROSLI M U， ISHAK M I， et al. Simulation⁃Based Optimization of Plastic Injection Molding Parameter for Aircraft Part Fabrication Using Response Surface Methodology （RSM）［J］. Materials Science and Engineering， 2019，551（1）.
13	CHEN Y F ， ZHU J J. Warpage Analysis and Optimization of Thin⁃walled Injection Molding Parts Based on Numerical Simulation and Orthogonal Experiment［J］. Materials Science and Engineering，2019，688.
14	戚传振. 可视化导光板注射压缩模具的设计与实验［D］. 北京：北京化工大学， 2013.
15	HIM L W. Injection Compression Molding （ICM） process development for the warpage and stress reduction on polymeric microfluidic chip applications［D］.Singapore： Nanyang Technological University，2020.
16	郭丽娜. 聚碳酸酯汽车玻璃注塑压缩成型数值模拟与实验研究［D］. 黑龙江：哈尔滨工业大学，2013.
17	KIMA B， MIN J. Residual Stress Distributions and Their Influence on Post⁃manufacturing Deformation of Injection⁃molded Plastic Parts［J］. Journal of Materials Processing Technology，2017，245：215⁃226.
18	杨虎振. 基于CAE技术的注塑制品翘曲变形研究［D］. 江苏：江苏大学，2008.
19	李欣欣. 薄壁件注射成型的翘曲变形分析与工艺优化［D］. 江苏：江苏大学，2010.
20	CAO W， MIN Z， ZHANG S， et al. Numerical Simulation for Flow⁃induced Stress in Injection/Compression Molding［J］. Polym Eng Sci， 2016， 56（3）： 287⁃98.
21	CAO W， HUA S， ZHANG S， et al. Three⁃Dimensional Viscoelastic Simulation for Injection/Compression Molding Based on Arbitrary Lagrangian Eulerian Description［J］. Journal of Computational and Nonlinear Dynamics， 2016， 11（5）.
22	严波，李阳，赵朋，等. 基于改进有限体积法的三维注塑成型充模过程数值模拟［J］. 机械工程学报，2015，51（10）：25⁃32.
	YAN B， LI Y， ZHAO P， et al. 3D Simulation of Filling Stage of Plastic Injection Molding Based on Improved Finite Volume Method［J］. Journal of Mechanical Enginee⁃ring， 2015，51（10）：25⁃32.
23	曾攀. 有限元分析及应用［M］. 清华大学出版社， 2004：344⁃357.

[1]	HUANG Xuemei, LIU Hesheng, HUANG Xingyuan, YU Zhong, JIANG Shiyu. Numerical simulation and experimental study on gas⁃assisted extrusion process of U⁃shaped parts [J]. China Plastics, 2022, 36(7): 93-103.
[2]	LIU Zheng, LIU Zhenfeng, ZHOU Guofa. Simulation study on regulation mechanism of key quality attributes of twin⁃screw wet granulation [J]. China Plastics, 2022, 36(6): 100-107.
[3]	DENG Shixin, WANG Jian, YANG Weimin. Simulation and analysis of fluid high⁃pressure and high⁃speed collision in mixing head cavity of enhanced reaction injection molding machine [J]. China Plastics, 2022, 36(6): 130-136.
[4]	ZHANG Qingtao, BI Chao. Numerical simulation of flow process of pellets in underwater⁃pelletizing device based on CFD⁃DEM [J]. China Plastics, 2022, 36(6): 87-91.
[5]	HE Hezhi, XU Li, YANG Yike. Effect of prestress on mechanical properties of PC/CF laminates [J]. China Plastics, 2022, 36(4): 1-5.
[6]	JIANG Jingwei, LIU Zhenfeng, ZHOU Guofa. Study on mixing uniformity regulation and control of continuous twin⁃screw mixer [J]. China Plastics, 2022, 36(4): 142-148.
[7]	BAN Dongdong, WANG Danhua, LIU Kui, LI Yanan, LI Han, DAI Yahui. Numerical simulation on mixing properties of wavy twin⁃screw elements [J]. China Plastics, 2022, 36(4): 95-101.
[8]	ZHANG Xiang, YAN Zhenhao, KONG Xiaoya, ZHU Jianxiao, GUAN Guotao, ZHAO Na, LI Qian. Study on structural optimization of disc screw in micro injection machine [J]. China Plastics, 2022, 36(2): 147-156.
[9]	LI Yongqing, YANG Xiaolong, CHEN Wenjing, YAN Xiaokun, MA Xiuqing. Molecular dynamics simulation of modifier and high⁃density polyethylene intercalate and exfoliate montmorillonite [J]. China Plastics, 2022, 36(2): 67-74.
[10]	YU Zhixing, LI Yingcheng, WANG Hongxue, PANG Xinlei, WANG Yuyao. Study on laser direct structuring materials based on polyamide 6 and polycarbonate and their fabrication of parts with heterostructure [J]. China Plastics, 2022, 36(2): 8-12.
[11]	LUO Fei, LI Cuijuan, LIU Zhuojia, LIU Yuxin, SHI Suyu, DANG Xudan, LIU Chuntai, ZHAO Yongtao. Study on Relationship between Molecular Orientation and Dynamic Viscoelasticity of Polycarbonate [J]. China Plastics, 2021, 35(9): 81-86.
[12]	ZHA Yan, ZHENG Fangli, XIAO Jian, YANG Weimin, XIE Pengcheng. Research on the Application of Co⁃simulation in the Reduced Design of Automotive Injection Parts [J]. China Plastics, 2021, 35(8): 112-116.
[13]	DONG Xingtong, WANG Xiangdong, SUN Xiaohong, CHEN Shihong. Research Progress in Density Functional Theory Used in Field of Polymer Foaming [J]. China Plastics, 2021, 35(7): 126-133.
[14]	SHENG Tianyang, TAN Jing, ZHANG Zhenghe, GAO Xiaodong, YU Jingchao, CHENG Lisheng, YANG Weimin. Numerical Simulation of Polyacrylonitrile Gel Flow Characteristics in Laminated Runner [J]. China Plastics, 2021, 35(7): 74-79.
[15]	WANG Ruizhe, LIU Hesheng, HUANG Xingyuan, YU Zhong, JIANG Shiyu, LIU Tongke. Effect of Different Air Intake Angles on Gas⁃assisted Extrusion of Sheet Polymer [J]. China Plastics, 2021, 35(7): 80-86.